Rotary welding transformer



Nov. 14, 1933; T, M HUNTER 1,934,856

ROTARY WELDING TRANSFORMER Filed June 28, 1952 5 Sheets-Sheet 1 INVENTOR 77/0M/95 M flZ/A/TE ATTORNEY Nov. '14, 1933. T. M. HUNTER 191M8 RO'iARY WELDING TRANSFORMER Filed June 28, 1932 5 Sheets-Sheet 2 m M I ATTORNEY Nov. 14, 1933. T. M. HUNTER ROTARY WELDING TRANSFORMER Filed June 28, 1932 5 Shegts-Sheet 3 INVENTOR 77/QM/7S/V Hwvra? ATTORNEY Nov. 14, 1933.

T. M. HUNTER ROTARY WELDING TRANSFORMER Filed June 28, 1932 5 Sheets-Sheet 4 ATTQRNEY Nov. 14, 1933 T. M. HUNTER ROTARY WELDING TRANSFORMER Filed June 28. 1932 s Shee't s-Sheecl INVENTORI a 77/dM/7JM Hu/v 75,?

BY n

a fix ATTORNEY Patented Nov. 14, 1933 UNITED STATES ROTARY WELDING TRANSFORMER Thomas M. Hunter, lllast Grange, N. J3. Application June 28, 1932. Serial No; 619,760 a; Claims. (or. 219-) This invention relates to the design of a transformer of the rotary type which is particularly adapted for use in welding metal, especially heavy wall tubing. In the design of a rotary transformer for welding such tubing, the current used is extremely large, on the order of hundreds of thousands of amperes, and one of the greatest problems is to cool the operating parts of the machine whereby the size of theseparts and hence the cost of the whole machine may be kept to a minimum.

in my application, Serial No. 517,176, filed February 20, 1931, I have shown and described a rotary transformer having a very large current capacity, and I have illustrated therein various details of construction whereby the transformer may be cooled. From the experience gained in the building of such a transformer-as shown in said patent application, 1 have evolved the im-- provements in the various detailed constructions which are the subject matter of the present application.

It istherefore the principal object of my present invention to provide an improved type of construction by which such a rotary transformer Figure 6 is acviewon the plane 6-6 pf Figure 3.

Fi e 7 is a View en the plane 7+7 bf Figure 3. Figure 8 is a plan view looking down on the ends of the primary and secondary ponductors along the line 8 8 of Figure 3 or'it is looking down on the tops of the views showniin Figures 9 d and 10, the parts of Figure 9 being at the extreme right in Figure 8, while are next adiacentl Figure 9 is a view on the line 9-9 of Figure 3, and is also a view on the same line, looking from right to left, in Figure 8.

Figure 1G is a view on the line 10-'-l 0 of Figure 3,-and is alsoa view on the same line of Figure 8. Figure 11 15a section on the line 11-11 of Figure 12. I, Y

Figure 12 is an'end-view of Figure 11.

the parts of Figure 10 Figure 13 is a section on Figure 11. I I a Figure id is a section on the line -l4'l4 of' Figure ll.

Figure 15 is a fragmentary section taken on the line. 15-15 of Figure 11.,

Referring now to the drawings, wherein like numbers refer to corresponding parts in the various views, 1 is a rotary transformer structure carried. on a shaft 2 supported in any satisfactory 95 manner between-the pedestals 3 and 4 which are insulated by the insulators 5 from a basesupport member 6. The reasonfor insulating the pedestals 3 and 4 from the base 6 will be seen from Figure 3, because. the interior construction of the transformer is such that the shaft 2 is in electrical contact with the secondar: circuit; As will be seen from the description which follows, the outer surface of the transformer-is com- 4 pletely enclosed with a cooling jacket, but for the purpose of simplification in the drawings, the straps which are used for assisting in holding these watenjackets in position are not illustrated.

By reference to Figure 3, it will be seen that the shaft 2 has mounted thereon, preferably by a forced fit as well as one or more keys, a secondary support and cooling drum 7 which is hollow and closed at one end by a closure plate 8 which engagesa gasket 9. ,The plate 8 is held in position by bolts 10 engaging the,spaced annular rims of the drum 7. The plate 8 is pro-i vided with oneor more holes' tappedwith a pipe thread to receive pipes 11 which extend from a headerpipe 12, from which an voutlet pipe 1:190 extends into a hollow outlet portion 14 of the shaft 2. The plate 8 is also provided withadditional openings which are provided withpacking glands 15 to receive inlet supply pipes 16 which the line 13-13 of in turn lead from a header 17 that is connected through a pipe 18, to an inlet supp y Pipe '19 centrally mounted with respect to the shaft cen-.

ter 2.

The pipes 16 preferably extend the length of the drum 7 and each endby a riser 20, opening into a space 21 formed in the front end of the drum '7. Thus, the cooling fluid is forced outwardly from the risers 20 directly against the flanged end 22 of the drum '7, which end is fastened by means of bolts 23 to a flange 24 hav ing an integral annular sleeve 25 positioned on a collar 26 forced on theshaft 2. The sleeve 25 is provided with a plurality of openings 27 which are closed off by the collar 26, and the openings 27 open into a fluid-cooling chamber 110.

- roll 43.

, .ondary conductor parts tothe roll 43.

28. By reason of this construction, a large area of cooling surface is provided for the sleeve by reason of the openings 27 through which the cooling fluid in the chamber 28 circulates.

The chamber 28 is formed on the side of one of the welding rolls 29 by attaching thereto, by means of bolts 30, a plate 31 having a rim 32 to fit against an annular gasket 33. Cooling fluid is led by one or more pipes 34 and nipples 35 into art annular ring 39 having holes through which the cooling fluid is sprayed into the chamber 23 against the surface of the roll 29, it being noted that on the front end of the machine the water outlet is through the pipe 36 located at the center of the shaft 2. The pipe 36 is connected by one or more nipples 37 leading into an annular space 38 into which the ends of the openings 2'7 extend.

The roll 29 carries a contact shoe 41 which is preferably arranged in sections in cooperation with corresponding shoes 42 carried on a second The shoes 41 and 42 are fastened to the=rolls 29 and 43 by bolts 44, which bolts also serve to fasten sectional members 45 and 46 to the shoes 41 and 42 respectively to provide cooling chambers 47 and 48. The cooling chamber 4'7 may be fed by the same pipe 34 which supplies the chamber 28, while the cooling chamber 48 is supplied by a supply pipe 49.

and 46.

The roll 43 is press-fitted and welded or brazed to a sleeve 54 preferably forming an integral part of an annular flanged member 55 positioned adjacent, but insulated from the flange member 24. The sleeve 54 is provided with a plurality of openings 56 (seev Fig. 5') which open into a cooling chamber 57, thus providing a large area of cooling surface for the sleeve 54 which carries the current from the outer sec- The cooling chamber 5'7 is closed by a somewhat peculiarly-shaped member 58 which-is provided with an annular flange 59 bolted by bolts 60 to the roll 43, a gasket being used under the flange 59 to insurers. fluid-tight joint. Likewise, the

member 58 is provided with another flange 61 which is bolted by bolts 62 which are attached to the upper part of the flanged member 55, a gasket being used around that portion of the member 58 which bears against the member 55 and through which the bolts 62 extend.

The cooling chamber 5'7 is provided with an annular ring 63 having holes 64 through which the cooling fluid, coming from one or more pipes 65, is thrown against the surface of the roll 43. The cooling chamber 57 is also provided with another annular pipe 66 which has open-' cooling the rolls and adjacent parts to be so The several cooling chambers 47 are supplied with an efficient that the current delivered to the shoes 41 and 42 may be greatly increased over any previous designs, without increasing the currentcarrying parts.

The secondary-support and cooling drum 7 has its outer periphery slotted or grooved as'indicated by the dotted line 68 to receive the inner edge 69 of an inner part '70 of a secondary turn, it being understood that all of the secondary turns pass around the core '71. Each alternate inner secondary end-turn is fastened by bolts '72 to a pair of risers '73 (see Fig. '7) which fork at their outer ends, one fork, 74, being fastened by bolts '75 to a bar '76, while the other fork-end, 77, is fastened to bar '78. The bars '76 and '78, which together form a single conductor, are extended longitudinally over the top of the core '71 (Fig. 8) and pass through slots in the flange 24, being insulated therefrom by insulators '79, and then project into slots in the outer periphery of the flanged member 55, where they are wedged in grooves or slots in the flange by the wedges 80. which preferably are of metal, although insulating ,wedges may be used provided the insulation is sufficiently strong, these wedges-being drawn radially inwardly by the nuts .82 on the studs or bolts 81 which are tapped into the periphery of the flange 55.

The front or roll ends of the inside secondary portion '70 are provided with .Lshaped risers 83. The risers 83 are joined by two bars 84 and 85 (see Fig. 8) to the flange 24 by reason of slots in the periphery of the flange 24 into which the bars 84 and 85 extend. Going back to the rear end of the inner secondary bars, it will be seen that alternate turns are differently arranged (see Fig. '7') as the alternate ends of bars '70 drop downwardly adjacent the end of the core and are bolted by bolts 86 to bars which correspond in general structure to '76 and '78. This arrangement is necessary in order to get at the bolts '72 and 86 for fastening the 'risers to the bar ends.

The primary turns are sandwiched alternately between the secondary turns around the core '71 and indexed to the same spacing as the inner secondary ba'r portions, and each turn is composed of two conductors 8'7 and 88 in parallel, being insulated from the secondary turn by suitable insulators 89, and preferably spacers 90 are driven in to hold the primary securely in position. The ends of'the primary are connected.

to slip rings 91 and 92 (see Fig. 3) which are insulated from each other by suitable insulators. The rings 91 and 92 are suitably mounted and insulated from a bracket 93 carried on part of the machine.

An important feature of my invention is the manner .of cooling the primary and the outer turns of the secondary bars. This construction is illustrated in detail in Figures 6 and 11 to 15 inclusive. By reference to these figures, it will be seen that the outer secondary turns are fastened to an arcuately-formed plate 94. The plate 94 is of non-magnetic metal and preferably slotted to receive the outer edges of the secondary bars '76 and '78, the bars being sweated or welded to the plate. The arcuately-formed plate 94, as shown in Figure 6', is approximately sixty degrees and it is attached to a rectangularly-shaped attached in relation to the arcuately-formed plate .5

This frame construction, com- 94 and the arcuatelyformed-plate 99, thereby completing'a cooling chamber in direct association with the outer turns of the primary and secondary bar. The manner of holding the plates 94 and 99 to the frame is indicated in Figure 14,

wherein arivet 104 is upset intoposition to draw the plates 94 and 99 securely against the parts of the frame. In addition, small spacing blocks are distributed intermediate the frame members as is indicated in Figure 11, these small support blocks being tied to the plates 94 and 99 in the same manner. 1 i

Extending across the center of the frame and v between the plates 94 and 99 is a baiile 100, the

end of which is indicated at 101 (see Fig. 11).

The cooling fluid is fed to one of the compartments formed by the baflle' 100, by the pipe 102;.

and after passing through this compartment and around the end 101 of the baflie, leaves the other compartment by way of the pipe 103.

While indicating the arcuate length of the secondary section just described in Figure 6 as being sixty degrees, it is to be understood that this sector can be of some other arcuate length, but

the object isto make the outer primary and secondary turns, with their cooling means, in separate, individual imits, whereby they may be fabricated more easily and cheaply and the assembly operations materially speeded up. Fur- 39 thermoraif anything goes wrong with the bar or connection in one 'of the sectors; only this one need be dismantled. thereby making a great sav ing in the cost of repairs.

From Figure 3, it will be noted that a supply pipe 105 leads from the hollow shaft end 2 to a distributing fitting '106 from which pipes lead to circular headers 107, 108, and 109, from which point the various supply pipes leadto the different cooling chambers which have been heretofore 46 described. These supply lines may be equipped with an individual control valve, or a valve may be inserted in the feed lines from the member 106,

0 rings, as well as, the header pipes just described,

the rear end of the machine is equipped'with a casing comprisinga cover member 112 carried on a stationary part of the transformer, and a cover 113. ,Since these parts are stationary; the

5 112 is provided with a packing 114, and the flanged member 115 is provided with packing 116 to" cooperate with the cover 113. 1 The member 115 is provided with a hub 11': carried on'ia collar 118 on the shaft 2. .The flanged member 115 is fastened by a plurality of bolts 119 to the front end cover member 120, therebysubstantially covering, in combination with the outer water jacket, the entire machine.

, It will be noted from Figure 3. that I have provideda very large cooling space within the rests directly on the drum, are exposed to this.

- interior of the machine by reason of the drum 'l which carries a large amount'of cooling 'flu'id' so that the inner portions of both primary and secondary, and especially the secondary which cooling area.

This feature, together with many others which have .been \described, I believe to be new and novel, and I therefore do not wish to be unduly limited in the interpretation of the appended welding transformer.

Having thus described-my invention, what I claim is:- a

1. A rotary welding transformer including a shaft, a cooling drum carried on the shaft, a core spaced from said drum, primary and secondary conductors'looping around said core, the inner parts of said loops being between said drum and the core, the inner secondary parts being directly mountedton the outer surface of said drum, welding rolls positioned adjacent one end of the drum, means for connecting said inner secondary conductor parts to one of said rolls, means for connecting the other roll to the outer parts of said secondary conductors, and means for conveying cooling fluid to and from the interior of said claims directed at my improved form of rotary 2. A rotary welding transformer as set forth in claim 1, further. characterized in that the outer surface of the cooling drum. is grooved and; said inner secondary parts are mechanically fastoned and electrically connected to said drum.

3. A rotary welding transformer as set forth in claim 1; further characterized in that said connecting means for said inner secondary conductor parts includes a flanged sleeve, the sleeve carry ing, in electrical contact, one of said welding rolls while the flange is'fastened tosaid cooling drum.

4. A rotary welding transformer as set forth in claim 1, further characterized in that said drum has a hollow flange, the hollow part of the flange opening into the main interior part of the drum, and still further characterized'in that said connecting means for said inner secondary conductor parts includes a flanged sleeve, the sleeve carrying, in electrical contact, one of 'said'welding rolls while the flange is fastened to said cooling drum.

5. A rotary welding transformer as set forth in claim 1, further characterized in that said drum hasfa hollow flange, the hollow part of the flange opening into the main interior part of the drum, and still further characterized in that said connecting means for said inner secondary conductor parts includes a flanged sleeve, the sleeve carrying, in electrical contact, one of said welding rolls while the flange is fastened to said cooling drum, and still further characterized in that thecooling fluid is discharged into the drum from one or more pipes leading into the upper part of the hollow part of the drum flange as and for the purpose described.

6. A rotary welding transformer as set forth in claim 1, further characterized in that said connecting means for said inner secondary conductorparts includes a flanged sleeve, the sleeve carrying both of said rolls, one insulated and the other in direct electrical contact therewith, while .the flange is fastened to said cooling drum.

7. A,rotary welding transformer as set forth in claim 1, further characterized in that said connecting means for said inner secondary cons ductor parts includes a flanged sleeve, the sleeve carrying both of said rolls, one insulated and the other indirect electrical contact therewith, while the flange is fastened to said cooling drum, and "still further characterized in, that said sleeve isfltted over a collar carried on the shaft, the

sleeve surface toward the collar having ,a plu- 1 -rality of depressions therein, thereby forming,

with the collar a cooling chamber of considerable area, and means for conveying cooling fluid to said last-mentioned chamber.

Wil

8. In a rotary welding transformer including a a 1 fluid to said chambers.

core and primary and secondary conductor turns looped around said core, a pair of welding rolls adjacent one end of the core and forming the terminals of said secondary turns, a cooling chamber on one side of each of said rolls, each of said chambers having a header pipe located therein with means for supplying cooling fluid thereto, said header pipes having holes therein whereby the cooling fluid coming from said headers is directed against the surface of said rolls.

9. In a rotary welding transformer including a core and primary and secondary conductor turns looped around said core, a pair of welding rolls adjacent one end of the core and forming the terminals of said secondary turns, a cooling chamber on one side of each of said rolls, means located at the radially outward parts of said chambers for directing the cooling fluid against said rolls, and means for taking the fluid away from said chambers.

10. A rotary welding transformer set forth in claim 8, further characterized in that the cooling chamber on the roll nearest the core is provided with a discharge header, the same being separated from the intake header by a baflle.

11. A rotary welding transformer as set forth in claim 1, further characterized in that said connecting means for said inner secondary conductor parts includes a flanged sleeve, the sleeve carrying both of said rolls, one insulated and the other in direct electrical contact therewith, while the flange is fastened to said cooling drum, and still further characterized in that said sleeve is ,fitted over a collar carriedon the shaft, the sleeve surface toward the collar having a plurality of depressions therein, thereby forming with the collar a cooling chamber of considerable area, and still further characterized in that at least one of said rolls has a cooling chamber and means for. passing the cooling fluid therefrom into the cooling chamber formed by said collar and said sleeve. I

12. A rotary welding transformeras set forth in claim 1, further characterized in that said connecting means for said inner secondary conductor parts includes a flanged sleeve, the sleeve carrying both of said rolls, one insulated and the other in direct electrical contact therewith, while the flange is fastened to said cooling drum, each of said rolls having a contact shoe, the shoes being held on the rolls in spaced relationship, cooling chambers associated with the shoes and with the rolls, and means for passing cooling 13. A rotary welding transformer as set forth in claim 1, further characterized in that saidconnecting means for said inner secondary conductor parts includes a flanged sleeve, the sleeve carrying both of said rolls, one insulated and the other in direct electrical contact therewith, while the flange is fastened to said cooling drum, each of said rolls having a contact shoe, the shoes being held on the rolls in spaced relationship, cooling chambers associated with the shoes and with the rolls, and means for passing cooling fluid to said chambers, the same means for holding the shoes to the rolls also serving to hold the cooling chainbers to the shoes.

14. In a rotary welding transformer including a core and primary and secondary conductor turns looped around said core in intermingled relationship, a. pair of welding rolls adjacent one end of the core forming the terminals of the secondary turns, a flanged sleeve positioned between one of said rolls and the outer parts of said secondary turns, the sleeve part carrying the roll, and the flange of said member being slotted to receive the ends of said outer secondary turns, and means including wedges, studs threaded into the periphcry of said flange, and nuts on the studs for tastening said secondary turn-ends to said flanged member.

15. In a rotary welding transformer including a core and primary and secondary conductor turns looped around said core in intermingled relationship, a pair of welding rolls adjacent one end of the core forming the terminals of the secondary turns, a flanged sleeve positioned between one of said rolls and the outer parts of said secondary turns, the sleeve part carrying the roll, and the flange of said member being slotted to receive the ends of said outer secondary turns, and means carried by the flange Ior fastening said secondary turn-ends to said flange.

16; A rotary welding transformer including a shaft, a cooling drum carried on the shaft, 2. core spaced from said drum, primary and secondary conductors looping aroimd said core, the inner parts of said loops being between said drum and the core, the inner secondary parts being directly mounted on the outer surface of said drum, and means for connecting the ends of the secondary turns to said rolls, said means including a pair of flanged sleeves,'the flanges and sleeves being in adjacent relationship respectively, and separated by insulation, one roll engaging the end oi. one sleeve andthe other roll the end of the other sleeve, the flanges being slotted, the one 'to receive the ends of the outer parts of the secondary turns while the other receives the ends of the inner parts of said turns, and means for passing cooling fluid through said drum.

17. A rotary welding transformer as set forth in claim 16, characterized in that the drum has a flange which is fastened to the flange of the inner of said flanged member, and the slots in the flange of saidinner flanged member being large enough to allow the necessary ends of the secondary turns topass therethro'ugh to the flange of the outer flanged member.

18. Arotary welding transformer including a core and primary and secondary conductor turns looped around saidcore in intermingled relation, a pair of welding rolls adjacent one end of the core and forming the terminals of said secondary turns, the conductors of said turns being arranged in separate independent sectors each composed of a plurality of generally parallel secondary conductors fastened together as a unit as and for the purposes described.

19. A rotary welding transformer as set fort in claim 18, characterized in that each primary turn is made up of at least two multiple conductors insulated from and wedged between secondary conductors.

20. A rotary welding transformer as 'set forth in claim 18, characterized in that the outer secondary conductor parts are mechanically and electrically connected to an arcuately-formed plate a second plate being fastened to the first in spaced relation, thereby forming a cooling chamber, while the outer primary conductors are wedged between the secondary conductors with means for looped around said core in intermingled relation..

a pair of welding rolls adjacent one end of the core and forming the terminals of said secondary turns, the conductors of said turns being arranged in separate independent sectors, said sectors including a pair of arcuately formed plates spaced apart to form a cooling chamber with means provided for passing a cooling fluid therethrough, the inner part of the inner plate being grooved to receive the edges of the outer secondary bar conductors which are fastened in said grooves, said outer primary turns being wedged between the secondary turns.

22. A rotary welding transformer as set forth in claim 21, characterized in that said plates are separated at their edges by a rectangular frame and spaced blocks at different points within said frame.

23. A rotary welding transformer including a shaft, a cooling drum on the shaft, a core, a pair of welding rolls, each having a cooling chamber associated therewith, primary and secondary conductors looped around the core and supporting it on said shaft over the drum, said rolls being the'terminal electrodes for the secondary turns, the outer conductor parts being arranged in sectors, said sectors comprising a pair of spaced former from which pipes lead to the cooling chamber, and further characterized in that a covering means is provided for covering said headers and the means for supplying current to the primary.

THOMAS M. HUNTER. 

